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Integrated Waste Management: Adding Value to Oil and Gas Industry Residues Through Co-processing

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Abstract

In developing countries, the sustainable management of materials into a circular economy framework is conditioned by several constraints, being economic limitations one of the most relevant. Integrated waste management could effectively aid in overcoming them. This work presents an exhaustive analysis from both economic and environmental points of view addressing the selection and design of treatment alternatives for the integrated management of urban and industrial wastes. We propose a mixed-integer mathematical programming formulation to determine the optimal set of treatments to convert wastes into energy, marketable products or innocuous materials, and we endorse the environmental performance through a life cycle analysis. In our case study, urban wastes include sewage sludge and municipal solid waste, while industrial wastes come from two sources: drill cuttings (an important oil and gas industry residue) and seasonal pomace waste from fruit processing. Treatment alternatives comprise anaerobic digestion, composting, recycling, bioremediation, compost amendment, thermal desorption and final disposal in landfill. Results for different scenarios show that even though the most profitable alternative is to dispose drill cuttings in landfills while processing organic wastes by anaerobic digestion, integrated management using biological treatment alternatives provides a more sustainable and still profitable strategy. We also demonstrate that the process integration increases the profitability and reduces the environmental impact significantly when compared with separate treatment alternatives for waste streams.

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Data Availability

The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.

Abbreviations

AD:

Anaerobic digestion/digester

CHP:

Combined heat and power

FE:

Freshwater eutrophication

FET:

Freshwater ecotoxicity

FPMF:

Fine particulate matter formation

FRS:

Fossil resource scarcity

GWP:

Global warming

HT:

Human toxicity

IR:

Ionizing radiation

LU:

Land use

MRS:

Mineral resource scarcity

MSW:

Municipal solid waste

O&G:

Oil and gas

ODC:

Oil-based drill cuttings

OFo:

Ozone formation

OF:

Organic fraction of municipal solid waste

PW:

Pomace waste

SS:

Sewage sludge

TA:

Terrestrial acidification

TE:

Terrestrial ecotoxicity

WC:

Water consumption

WDC:

Water-based drill cuttings

B :

Available potential anaerobic digesters

D :

Possible temperature regimes for the AD

I :

Types of substrate

K :

Fruit company

P :

Period within an annual period t with PW availability

T :

Annual periods of the time horizon

dist dc :

Average distance between the wells zone and the co-processing plant

dist k :

Distance between the fruit company k and the co-processing plant

dm c :

Dry matter content after centrifugation

dm comp :

Dry matter content of compost

dm d :

Dry matter content for the AD inflows

dm db :

Dry matter content after drying bed

dm i :

Dry matter content of every substrate i

dm SS :

Dry matter content of SS

fcdc :

Unit freight cost of drill cuttings

fcpw :

Unit freight cost of fruit pomace

k d,i :

First order reaction rate constant at temperature regime d, processing the substrate i

r :

Annual discount rate

vs i :

Volatile solids concentration in substrate i

x M :

Volumetric fraction of methane in the biogas

ym d,i :

Ultimate methane yield per unit of volatile solids in substrate i in a AD under regime d

ε CH4 :

Higher heating value of methane

ρ biogas :

Biogas density in normal conditions

ρ f :

Substrate density

CA :

Capital cost of compost amendment infrastructure

CB :

Capital cost of bioremediation process infrastructure

CC :

Capital cost of composting infrastructure

Ccf:

Capital cost of centrifuge process infrastructure

CD :

Total capital cost of ADs infrastructure

Cdb :

Capital cost of drying bed infrastructure

CHPe p :

Total electricity generated during period p

CHPt p :

Total heat generated during period p

CL :

Capital cost of landfill sites

Cs :

Capital cost of the separation plant

CT ODC,p :

Annual transportation cost of oil-based drill cuttings during period p

CT WDC,p :

Annual transportation cost of water-based drill cuttings during period p

CT p :

Operating costs of thermal desorption during period p

CT PW,p :

Annual transportation cost of fruit pomace during period p

HRT d,b,p :

Hydraulic retention time in the AD b, running under regime d, during period p

IC p :

Income from selling compost as organic fertilizer during period p

Idb p :

Income from selling dried digestate as organic fertilizer during period p

ID p :

Income from selling the electricity and the certified emission reductions (CER) generated during period p

Isp p :

Income from selling recyclable materials during period p

NPV :

Net present value

OA p :

Operating costs of compost amendment during period p

OB p :

Operating costs of bioremediation during period p

Ocf p :

Operating costs of centrifuging during period p

OC p :

Operating costs of composting during period p

Odb p :

Operating costs of the drying bed during period p

OD p :

Operating costs of AD during period p

OL p :

Operating costs of landfill sites during period p

OS p :

Operating costs of the separation plant during period p

QA WDCp :

Mass flow-rate of WDC sent to compost amendment process during period p

QB ODC :

Mass flow-rate of ODC sent to bioremediation process

QB OF :

Mass flow-rate of OF sent to bioremediation process

QB PW,p :

Mass flow-rate of PW sent to bioremediation process during period p

QB SS :

Mass flow-rate of SS sent to bioremediation process

QCa p :

Mass flow-rate of compost sent to compost amendment process during period p

QCfe p :

Mass flow-rate of compost commercialized as organic fertilizer during period p

QC OF :

Mass flow-rate of OF sent to the composting plant

QC p :

Mass flow-rate of compost generated in period p

QC PW,p :

Mass flow-rate of PW sent to the composting plant during period p

QC SS :

Mass flow-rate of SS sent to the composting plant

Qdba p :

Total flow-rate that leaves drying beds, during period p, sent to compost amendment

Qdbf p :

Total flow-rate that leaves drying beds, during period p, sold as organic fertilizer

QD OF d,b,p :

Mass flow-rate of OF sent to AD b, running under regime d, during period p

QDPW d,b,p :

Mass flow-rate of PW sent to AD b, running under regime d, during period p

QDSS d,b,p :

Mass flow-rate of SS sent to AD b, running under temperature regime d, during the period p

QGb d,b,p :

: Mass flow-rate of centrifuged digestate produced in AD b, running under regime d, during period p, sent to bioremediation process

QGc d,b,p :

Mass flow-rate of centrifuged digestate produced in AD b, running under regime d, during period p, sent to composting plant

QG d,b,p :

Mass flow-rate of digestate produced in AD b, running under temperature regime d, during the period p

QGdb d,b,p :

Mass flow-rate of centrifuged digestate produced in AD b, running under regime d, during period p, sent to drying bed

QG db,p : :

Total input flow-rate to drying beds during period p

QL ODC, p :

Mass flow-rate of ODC sent to landfills during period p

QL OF,p :

Mass flow-rate of OF sent to landfill during period p

QL p :

Mass flow-rate sent to landfill during period p

QL SS,p :

Mass flow-rate of SS sent to landfill during period p

QL WDC, p :

Mass flow-rate of WDC sent to landfills during period p

QM d,b,p :

Volumetric flow-rate of methane yielded by AD b, running under regime d, during period p

Q MSW ,p :

Mass flow-rate of municipal solid waste during period p

Q ODC :

Mass flow-rate of ODC

Q OF, p :

Mass flow-rate of OF from municipal solid waste during period p

Qot p :

Mass flow-rate of non-recyclable waste during period p

Q PW,p :

Mass flow-rate of fruit pomace waste during period p

Qr p :

Mass flow-rate of recyclable materials during period p

Qsp p :

Mass flow-rate sent to separation plant during the period p

Q SS p :

Mass flow-rate of SS during period p

QTD d,b,p :

Total inflow sent to AD b, running under temperature regime d, during period p

QTf p :

Inert material obtained after thermal desorption during period p

QT ODC,p :

Mass flow-rate of ODC sent to thermal desorption during period p

QT p :

Total mass flow-rate sent to thermal desorption during period p

QT WDC,p :

Mass flow-rate of WDC sent to thermal desorption during period p

QW d,b,p :

Mass flow-rate of fresh water sent to AD b, running under temperature regime d, during period p

Q WDC :

Mass flow-rate of WDC

QWG p :

Water fraction of the digestate after centrifugation during period p

QW SS,p :

Water fraction of the SS after centrifugation during period p

TTC p :

Total transportation cost over period p

V d,b :

Volume of every single AD b, running under temperature regime d

Y d,b,p,i :

Extent of reaction in the AD b, running under regime d, during period p, for the sustrate i

w d, b :

1 if a the digester b is installed running under temperature regime d

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Acknowledgements

The authors acknowledge the financial support received from the Universidad Nacional del Litoral, Consejo Nacional de Investigaciones Científicas y Técnicas (CONICET) and Fundación YPF (FYPF). We are also most grateful with Fernando Zurita for the data provided to us for the case study.

Funding

Funding was supported by Consejo Nacional de Investigaciones Científicas y Técnicas,Fundación YPF

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Authors and Affiliations

  1. INTEC (UNL-CONICET), Güemes 3450, 3000, Santa Fe, Argentina

    Betzabet Morero, Agustín F. Montagna & Diego C. Cafaro

  2. Facultad de Ingeniería y Ciencias Hídricas, Universidad Nacional del Litoral, Ruta Nacional Nº 168 Km 472.4, 3000, Santa Fe, Argentina

    Betzabet Morero

  3. Department of Chemical Engineering, Mid Sweden University, Holmgatan 10, 85170, Sundsvall, Sweden

    Gabriela L. Paladino

  4. Facultad de Ingeniería Química, Universidad Nacional del Litoral, Santiago del Estero 2829, 3000, Santa Fe, Argentina

    Agustín F. Montagna & Diego C. Cafaro

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  1. Betzabet Morero
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Morero, B., Paladino, G.L., Montagna, A.F. et al. Integrated Waste Management: Adding Value to Oil and Gas Industry Residues Through Co-processing. Waste Biomass Valor 14, 1391–1412 (2023). https://doi.org/10.1007/s12649-022-01908-5

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